Method of packing and shipping erosion control blankets

ABSTRACT

A method of packing and shipping erosion control blankets that maximizes the use of the interior space of a shipping container. More particularly, but not by way of limitation, the method relates to packing, handling, storing and shipping of erosion control blankets adapted for delivery to customers in generally cylindrical, rolled configurations.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority from, and incorporates byreference the entire disclosure of U.S. Provisional Patent ApplicationNo. 61/003770, filed on Nov. 20, 2007.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the packing and shipping of erosioncontrol blankets, and more particularly, but not by way of limitation,to the packing, handling, storing and shipping of erosion controlblankets adapted for delivery to customers in generally cylindrical,rolled configurations.

2. History of the Prior Art

For both aesthetic and environmental control reasons, it is oftennecessary or desirable to grow ground vegetation such as, for example,grass, on flat land or slopes, channels, and bare earth areas to inhibiterosion due to effects of wind and rain. The successful sprouting andgrowth of ground vegetation planted on these areas, however, is oftenprevented by soil erosion which planted vegetation is designed toinhibit, the erosion frequently carrying away at least some portion ofthe soil before vegetation takes hold.

To alleviate this problem, it is now a common practice to cover the areawith fibrous, mat-like members commonly referred to as erosion controlblankets. Erosion control blankets in general are discussed inco-pending U.S. patent application Ser. No. 09/648,906, assigned to theassignee of the present invention. One particularly effective erosioncontrol blanket is the CURLEX® or excelsior blanket manufactured andsold by the American Excelsior Company of Arlington, Texas since 1964.This erosion control blanket is fabricated, in elongated rectangular matform, from elongated, randomly intertwined fibers commonly referred toas excelsior or wood wool. The erosion control blanket assemblies aretypically packaged in individually rolled bundles to facilitate theirhandling and transport to the erosion control job site. The cost oftransportation is, therefore, a significant factor to be considered inthe purchase of the erosion control blankets.

Once packed, shipped and delivered to the job site, the erosion controlblanket bundles are unrolled in a side-to-side relationship along anearth area to be protected against erosion, and are secured along sidesof one another and to an underlying ground area with a use of a spacedseries of conventional ground staple members, which may be made of, forexample, steel, wood, plastic, starch, or the like. The installederosion control blankets generally have parallel sides and abut oneanother to form a substantially solid surface to shield the underlyingearth area, and thus the planted ground vegetation therein, from windand water erosion forces.

The individual fibers forming the mat portion of various types of theerosion control blankets collectively define therebetween a plurality ofsmall interstitial regions through which the planted ground vegetationmay upwardly sprout and grow. During such shielded vegetation growth,some varieties of the erosion control blankets, such as the CURLEX®blanket decompose, ultimately being replaced by the emerging groundvegetation.

The innovative approach to utilizing excelsior wood fibers in an erosioncontrol blanket has been found to be both economically viable andenvironmentally effective for erosion control considerations. Due to theever growing number of federal, state, and municipal regulationsrequiring protective measures in the area of erosion control, theshipment of and cost for delivery of such erosion control units hasbecome increasingly important. Due to the size and length of the erosionblankets, such as the above referenced CURLEX® erosion control blanket,shipping and handling is of major concern for both the manufacturer andan ultimate user. When the erosion control blankets are packed forshipment in a less then efficient manner, the amount of space necessaryfor shipment will be less cost effective. A need therefore exists for amethod of efficient, space-saving packaging and handling of erosioncontrol blankets in a manner facilitating reduced cost and ease instorage, packing, and use.

BRIEF SUMMARY OF THE INVENTION

Disclosed is a method of packing, handling, and delivering a pluralityof erosion control blankets of a type having a flexible mat ofintertwined, elongated members. The method comprises assembling theplurality of erosion control blankets for packing; providing a shippingcontainer having an interior width, an interior height, and an interiorlength; rolling each of the plurality of erosion control blankets into agenerally cylindrical shape; grouping the rolled plurality of erosioncontrol blankets into a plurality of bundles, each of the plurality ofbundles having a height and width that is generally evenly divided intothe interior height and width of the shipping container; and bindingeach of the plurality of bundles for subsequent handling.

In an alternative embodiment, a method of packing, handling, anddelivering a plurality of erosion control blankets of the type having aflexible mat of intertwined, elongated members. the method comprisesassembling the plurality of erosion control blankets for packing;providing a shipping container having an interior width and an interiorheight, wherein the interior width is generally an integer multiple of anumber 3y and the interior height is generally an integer multiple of anumber 2x; rolling each of the plurality of erosion control blanketsinto a generally cylindrical shape; grouping the rolled plurality oferosion control blankets into a plurality of bundles each having aheight of generally x, and a width of generally y; and binding each ofthe plurality of bundles for subsequent handling.

In yet another alternative embodiment, a method of packing, handling,and delivering a plurality of erosion control blankets of the typehaving a flexible mat of intertwined, elongated members. The methodcomprises assembling the plurality of erosion control blankets forpacking; providing a shipping container having an interior width, aninterior height, and an interior length; rolling each of the pluralityof erosion control blankets into a generally cylindrical shape having alength and a diameter; grouping the rolled plurality of erosion controlblankets into a plurality of bundles, each of the plurality of bundleshaving a height, width, and length that is generally evenly divided intothe interior height, width, and length of the shipping container; andbinding each of the plurality of bundles for subsequent handling.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiment of the invention will now be described, by wayof example only, with reference to the accompanying drawings in which:

FIG. 1 is a fragmentary perspective view of a sloping ground areacovered by a series of vegetation growth-enhancing erosion controlblankets;

FIG. 2 illustrates a flow diagram of a packing and handling process foran erosion control blanket;

FIG. 3 is a front elevation view of a shipping container containing abundle of rolled erosion control blankets according to FIG. 2;

FIG. 4 is a front elevation view of a shipping container of FIG. 3 withthe interior space efficiently filled with the erosion control blanketsgenerally oriented along a length of the shipping container;

FIG. 5 is a front elevation view of a shipping container of FIG. 3 withthe interior space efficiently filled with the erosion control blanketsoriented generally parallel to a height of the shipping container;

FIG. 6 is a front elevation view of a shipping container of FIG. 3 withthe interior space efficiently filled with at least some erosion controlblankets oriented generally parallel to the width of the shippingcontainer and at least some of the erosion control blankets orientedgenerally parallel to the length of the shipping container; and

FIG. 7 is a front elevation view of a shipping container of FIG. 3 withthe interior space efficiently filled with at least some erosion controlblankets oriented generally parallel to the height of the shippingcontainer and at least some erosion control blankets oriented generallyparallel to the length of the shipping container.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described more fully hereinafter withreference to the accompanying drawings in which the preferredembodiments of the invention are shown. This invention may, however, beembodied in many different forms and should not be construed as beinglimited to the embodiments set forth herein. Rather, the embodiments areprovided so that this disclosure is thorough and complete, and fullyconveys the scope of the invention to those skilled in the art. Whereverpossible, the same reference numerals are used throughout the drawingsto refer to the same or like parts.

FIG. 1 is a fragmentary perspective view of a sloping ground areacovered by a series of vegetation growth-enhancing erosion controlblankets. In FIG. 1, there is shown, in simplified form, a section ofground having a downwardly sloping earth portion 12 normally subject toundesirable wind and water erosion forces, and upon whicherosion-inhibiting ground vegetation 22 is to be grown. Covering thesloping earth portion 12 are a series of specially designed, vegetationgrowth enhancing, erosion control blankets 14. The erosion controlblankets 14, have porous construction through which a planned-for groundvegetation 22 may readily germinate and grow.

Referring still to FIG. 1, the erosion control blankets 14 haveelongated, generally rectangular configurations and are conventionallysecured to one another and to the underlying sloping earth portion 12,by a series of ground staples 16. Installed in this manner, the erosioncontrol blankets 14 shield the sloping earth portion 12 from both windand rain until the ground vegetation 22 takes hold.

Referring still to FIG. 1, each of the erosion control blankets 14includes an elongated rectangular mat 18 formed from fibrous materialsuch as, for example, a plurality of elongated fibers 20 disposed in arandomly intertwined relationship. In a typical embodiment, wood fibers20 of the excelsior or wood wool variety are preferably used andcollectively define therebetween a plurality of relatively smallinterstitial regions through which ground vegetation 22, for examplegrass, may upwardly grow from the sloping earth portion 12 protectivelycovered by erosion control blankets 14. Each mat 18 has a substantiallyflat bottom surface 24, positionable directly against the sloping earthportion 12.

FIG. 2 illustrates a flow diagram of a packing and handling for anerosion control blanket. FIG. 3 is a front elevation view of a shippingcontainer containing a bundle of rolled erosion control blankets 14according to FIG. 2. Referring now to FIGS. 2 and 3, a block diagramillustrates, by way of example only, the various steps of one embodimentof a packing process 300 which may be followed while preparing erosioncontrol blankets 14 for shipment in accordance with the presentinvention. FIG. 3 illustrates a shipping container 300 is providedhaving an interior height 304 and an interior width 302, allowingbundles 306 to be inserted therein. In a typical embodiment, shippingcontainer 300 may be any type of vessel suitable for shipping over land,air, or water, but is preferably an enclosed, van-style trailer.Interior height 304 and interior width 302 are, generally, an integermultiple of a number “x” and “y” respectively.

Referring specifically now to FIG. 2, the packing process 200 comprisesthe following steps: assembling erosion control blanket 14 for purposesof packing the shipment in step 202; providing a shipping container 300in step 204; rolling each of the erosion control blanket 14 into agenerally cylindrical shape in step 206; grouping the rolled erosioncontrol blanket 14 into bundles 306, having a height of approximately anumber x, whereby such a height, generally, divides substantially evenlyinto interior height 304 of shipping container 300 in step 208; applyingsecuring bands or tethers about the bundles 306 in step 210 to form apackaged assembly ready for handling. By way of example, bundles 306comprising fifteen erosion control blankets 14 are shown in FIG. 3, butany number of erosion control blankets 14 can be grouped together,provided that the height and width of the resulting bundles 306 can beapproximately evenly divided into the interior height 304 and interiorwidth 302 of shipping container 300.

Referring specifically now to FIG. 3, the rolled erosion controlblankets 14 may, for example, be bound by metal bands, tethers formed ofsynthetic material, and/or any other binding materials, such as, foreexample, rope, wire or the like providing appropriate strength withoutdamaging the rolled erosion control blankets 14 bound therewith. It maybe seen that when using a very narrow or sharp element, such as wire, itmay be necessary to incorporate a flexible member (not explicitlyshown), such as fabric, between the binding member (not explicitlyshown) and the erosion control blanket 14 to prevent tearing andpermanent damage to erosion control blanket 14.

FIG. 4 is a front elevation view of a shipping container of FIG. 3 withthe interior space efficiently filled with the erosion control blanketsgenerally oriented along the length of the shipping container. FIG. 4illustrates that the process of creating bundles having dimensions thatare generally evenly divided into the interior dimensions of theshipping container provides efficient use of the interior space ofshipping container 300, and reduces the time and labor associated withloading and unloading shipping container 300. It has been found thatbundles 306 containing fifteen erosion control blankets 14 arranged inan array of three wide by five erosion control blankets 14 highmaximizes the use of the interior space when shipping container 300 isan enclosed, van-style trailer. However, bundles 306 containingdifferent numbers of erosion control blankets 14 have been shown to bebeneficial depending on specific shipping requirements and spaceconstraints. For example, and not by way of limitation, an array ofthree erosion control blankets 14 wide by two erosion control blankets14 high also maximizes the interior space when shipping container 300 isan enclosed, van style trailer. An array of three erosion controlblankets 14 wide by two erosion control blankets 14 high may also bedesirable when it is necessary to ship smaller orders of erosion controlor when it is beneficial to reduce the overall size of the bundles 306.

FIG. 5 is a front elevation view of a shipping container of FIG. 3 withthe interior space efficiently filled with the erosion control blanketsoriented generally parallel to a height of the shipping container.Referring now to FIG. 5, an alternate embodiment of efficiently packinga shipping container 300 is shown. The erosion control blankets 14 areshown oriented such that the lengths of erosion control blankets 14 aregenerally parallel to interior height 304 of the shipping container 300.In this embodiment, bundles 306 comprise an array having dimensions thatare generally evenly divided into the interior dimensions of shippingcontainer 300. For example, and not by way of limitation, it may bedesirable for bundles 306 to comprise an array of three erosion controlblankets 14 wide by three erosion control blankets 14 deep. Alternately,it may be desirable for bundles 306 to comprise a different array thatwill make better use of the interior space of shipping container 300. Itshould be understood that various arrays could be utilized in order totake advantage of the size and shape of shipping container 300.

FIG. 6 is a front elevation view of a shipping container of FIG. 3 withthe interior space efficiently filled with at least some erosion controlblankets oriented generally parallel to the width of the shippingcontainer and at least some of the erosion control blankets orientedgenerally parallel to the length of the shipping container. Referringnow to FIG. 6, an alternate embodiment of efficiently packaging ashipping container 300 is shown. Erosion control blankets 14 are shownin shipping container 300 oriented in two different directions. A firstat least one bundle 306 of erosion control blankets 14 are oriented suchthat the lengths of the erosion control blankets 14 are generallyparallel to interior width 302 of shipping container 300. A second atleast one bundle 306 of erosion control blankets 14 are oriented suchthat the lengths of the erosion control blankets 14 are generallyparallel to the length of shipping container 300. In this embodiment,bundles 306 comprise an array having dimensions that are generallyevenly divided into the interior dimensions of shipping container 300.In this embodiment it may be desirable for bundles 306 to comprise twodifferent arrays, one array for the erosion control blankets 14 orientedgenerally parallel to interior width 302 of shipping container 300 andone array for the erosion control blankets 14 oriented generallyparallel to the length of shipping container 300. However, it is notnecessary for the arrays to be different. For example, and not by way oflimitation, it may be desirable for an array of five erosion controlblankets 14 by two erosion control blankets 14. Alternately, it may bedesirable for bundles 306 to comprise a different array that will makebetter use of the interior space of shipping container 300.

FIG. 7 is a front elevation view of a shipping container of FIG. 3 withthe interior space efficiently filled with at least some erosion controlblankets oriented generally parallel to the height of the shippingcontainer and at least some erosion control blankets oriented generallyparallel to the length of the shipping container. Referring now to FIG.7, an alternate embodiment of efficiently packaging a shipping container300 is shown. Erosion control blankets 14 are shown in shippingcontainer 300 oriented in two different directions. A first at least onebundle 306 of erosion control blankets 14 are oriented such that thelengths of the erosion control blankets 14 are generally parallel tointerior height 304 of shipping container 300. A second at least onebundle 306 of erosion control blankets 14 are oriented such that thelengths of the erosion control blankets 14 are generally parallel to thelength of shipping container 300. In this embodiment, bundles 306comprise an array having dimensions that are generally evenly dividedinto the interior dimensions of shipping container 300. In thisembodiment it may be desirable for bundles 306 to comprise two differentarrays, one array for the erosion control blankets 14 oriented generallyparallel to interior height 304 of shipping container 300 and one arrayfor the erosion control blankets 14 oriented generally parallel to thelength of shipping container 300. However, it is not necessary for thearrays to be different. For example, and not by way of limitation, itmay be desirable for an array of five erosion control blankets 14 by twoerosion control blankets 14. Alternately, it may be desirable forbundles 306 to comprise a different array that will make better use ofthe interior space of shipping container 300.

Referring now generally to FIG. 5, FIG. 6, and FIG. 7, it should berealized that any combination of orientations of erosion controlblankets 14 that maximizes the use of the interior space of shippingcontainer 300 is contemplated.

It is thus believed that the operation and construction of the presentinvention will be apparent from the foregoing description of thepreferred embodiments. While the erosion control blanket configurationsand designs as shown are described as being preferred, it will beobvious to a person of ordinary skill in the art that various changesand modifications may be made therein without departing from the spiritand scope of the invention as defined by the following claims.Therefore, the spirit and scope of the appended claims should not belimited to the description of the preferred embodiments containedtherein.

1. A method of packing, handling, and delivering a plurality of erosion control blankets of a type having a flexible mat of intertwined, elongated members, the method comprising: assembling the plurality of erosion control blankets for packing; providing a shipping container having an interior width, an interior height, and an interior length; rolling each of the plurality of erosion control blankets into a generally cylindrical shape; grouping the rolled plurality of erosion control blankets into a plurality of bundles, each of the plurality of bundles having a height and width that is generally evenly divided into the interior height and width of the shipping container; and binding each of the plurality of bundles for subsequent handling.
 2. The method according to claim 1, wherein the shipping container comprises an enclosed freight trailer.
 3. The method according to claim 1, wherein the shipping container comprises a vessel adapted for shipping by air or sea.
 4. The method according to claim 1, wherein the interior height of the shipping container is generally an integer multiple of a number x.
 5. The method according to claim 1, wherein the interior width of the shipping container is generally an integer multiple of a number y.
 6. The method according to claim 4, wherein a height of each of the plurality of bundles is approximately x.
 7. The method according to claim 6, wherein a width of each of the plurality of bundles is approximately y.
 8. The method according to claim 1, wherein each of the plurality of bundles comprises fifteen erosion control blankets.
 9. The method according to claim 8, wherein a height of each of the plurality of bundles is approximately one half of the interior height of the shipping container.
 10. The method according to claim 8, wherein a width of each of the plurality of bundles is approximately one third of the interior width of the shipping container.
 11. The method according to claim 8, wherein each of the plurality of bundles has both a height that is approximately one half of the interior height of the shipping container and a width that is approximately one third of the interior width of the shipping container.
 12. The method according to claim 1, wherein each of the plurality of bundles comprises six erosion control blankets.
 13. The method according to claim 12, wherein a height of each of the plurality of bundles is approximately one fifth of the interior height of the shipping container.
 14. The method according to claim 12, wherein a width of each of the plurality of bundles is approximately one third of the interior width of the shipping container.
 15. The method according to claim 12, wherein each of the plurality of bundles has both a height that is approximately one fifth of the interior height of the shipping container and a width that is approximately one third of the interior width of the shipping container.
 16. The method according to claim 1, wherein a geometry of the plurality of bundles generally maximizes an occupied space inside the shipping container.
 17. The method according to claim 1, wherein the step of binding the plurality of bundles comprises providing at least one band having opposite ends and securing the opposite ends around the plurality of bundles of rolled plurality of erosion control blankets.
 18. The method according to claim 17, wherein the at least one band is provided in a metal configuration.
 19. The method according to claim 17, wherein the at least one band is provided in a synthetic material configuration.
 20. A method of packing, handling, and delivering a plurality of erosion control blankets of a type having a flexible mat of intertwined, elongated members, the method comprising: assembling the plurality of erosion control blankets for packing; providing a shipping container having an interior width and an interior height, wherein the interior width is generally an integer multiple of a number 3y and the interior height is generally an integer multiple of a number 2x; rolling each of the plurality of erosion control blankets into a generally cylindrical shape; grouping the rolled plurality of erosion control blankets into a plurality of bundles each, each of the plurality of bundles having a height of generally x and a width of generally y; and binding each of the plurality of bundles for subsequent handling.
 21. The method according to claim 20, wherein the shipping container comprises an enclosed freight trailer.
 22. The method according to claim 20, wherein the shipping container comprises a vessel adapted for shipping by air or sea.
 23. The method according to claim 20, wherein a geometry of the plurality of bundles generally maximizes an occupied space inside the shipping container.
 24. The method according to claim 20, wherein each of the plurality of bundles comprises fifteen erosion control blankets.
 25. The method according to claim 20, wherein each of the plurality of bundles comprises six erosion control blankets.
 26. The method according to claim 20, wherein the step of binding the plurality of bundles of rolled plurality of erosion control blankets comprises providing at least one band having opposite ends and securing the opposite ends around the plurality of bundles of the rolled plurality of erosion control blankets.
 27. The method according to claim 20, wherein the band is provided in a metal configuration.
 28. The method according to claim 20, wherein the band is provided in a synthetic material configuration.
 29. A method of packing, handling, and delivering a plurality of erosion control blankets of a type having a flexible mat of intertwined, elongated members, the method comprising: assembling the plurality of erosion control blankets for packing; providing a shipping container having an interior width, an interior height, and an interior length; rolling each of the plurality of erosion control blankets into a generally cylindrical shape having a length and a diameter; grouping the rolled plurality of erosion control blankets into a plurality of bundles, each of the plurality of bundles having a height, width, and length that is generally evenly divided into the interior height, width, and length of the shipping container; and binding each of the plurality of bundles for subsequent handling.
 30. The method according to claim 29, wherein a geometry of the plurality of bundles generally maximizes an occupied space inside the shipping container.
 31. The method according to claim 29, wherein the plurality of bundles are oriented with a length of the plurality of erosion control blankets generally parallel to the interior width of the shipping container.
 32. The method according to claim 29, wherein the plurality of bundles are oriented with a length of the plurality of erosion control blankets generally parallel to the interior height of the shipping container.
 33. The method according to claim 29, wherein the plurality of bundles are oriented with a length of the plurality of erosion control blankets generally parallel to the interior width of the shipping container.
 34. The method according to claim 29, wherein at least one of the plurality of bundles is oriented such that a length of the erosion control blankets is generally parallel to the interior width of the shipping container and at least one of the plurality of bundles is oriented such that the length of the erosion control blankets is generally parallel to the interior length of the shipping container.
 35. The method according to claim 29, wherein at least one of the plurality of bundles is oriented such that the length of the plurality of erosion control blankets is generally parallel to the interior height of the shipping container and at least one of the plurality of bundles is oriented such that the length of the plurality of erosion control blankets is generally parallel to the interior length of the shipping container.
 36. The method according to claim 29, wherein each of the plurality of bundles has a height that is approximately one half of the interior height of the shipping container.
 37. The method according to claim 29, wherein each of the plurality of bundles has a width that is approximately one third of the interior width of the shipping container.
 38. The method according to claim 29, wherein the shipping container comprises an enclosed freight trailer.
 39. The method according to claim 29, wherein the shipping container comprises a vessel adapted for shipping by air or sea. 